Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001OE6H
Model Year Start: 2020 Model: RAV4 HV Prod Date Range: [06/2020 - 08/2020]
Title: HYBRID / BATTERY CONTROL: HV BATTERY STACK (for LITHIUM-ION BATTERY): REMOVAL; 2020 MY RAV4 HV [06/2020 - 08/2020]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during HV supply stack sub-assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedures

Effect/Inoperative Function when Necessary Procedure not Performed

Link

*: When performing learning using the Techstream.

Click here 2019 - 2022 MY RAV4 HV [02/2019 - 10/2022]; PARK ASSIST / MONITORING: PARKING SUPPORT BRAKE SYSTEM (for HV Model): CALIBRATION

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane control system

2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system*

Pre-collision system

Memorize steering angle neutral point

Parking assist monitor system

2019 - 2022 MY RAV4 RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM: INITIALIZATION

Panoramic view monitor system

2019 - 2022 MY RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

Reset back door close position

Power back door system

2019 - 2023 MY RAV4 HV [11/2018 - 10/2023]; DOOR / HATCH: POWER BACK DOOR SYSTEM (for HV Model): INITIALIZATION

Back door lock initialization

Power door lock control system

2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

  • Replacement of No. 1 HV supply stack sub-assembly
  • Replacement of No. 2 HV supply stack sub-assembly
  1. Battery status info update
  2. Prediagnostic battery charge
  3. Battery diagnosis

HV battery status information cannot be updated

2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HYBRID BATTERY SYSTEM (for LITHIUM-ION BATTERY): UTILITY

  • Replacement of battery ECU assembly
  • Replacement of HV battery junction block assembly

Current sensor offset learning

DTCs are stored

2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY): INSTALLATION+

Replacement of hybrid battery terminal block

Perform high voltage fuse accumulated load history reset

2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY): UTILITY

CAUTION:

  • Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    Click here 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY): PRECAUTION

  • To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.
  • The hybrid system has high-voltage circuits. Accidents, such as electric shock, or electric leaks may result if the hybrid system is not operated in a correct manner. Make sure to follow the correct procedure.
  • When disposing of an HV battery or HV supply stack sub-assembly, make sure to return them through an authorized collection agent who is capable of handling them safely.
  • Before returning an HV battery, make sure to perform a recovery inspection.
  • Before returning an HV supply stack sub-assembly, make sure to perform a recovery inspection.
  • Make a note of the output DTCs as some of them may be necessary for "Recovery Inspection" of the HV battery and HV supply stack sub-assemblies.

NOTICE:

  • When replacing the No. 1 HV supply stack sub-assembly or No. 2 HV supply stack sub-assembly, it is necessary to check, adjust and equalize the SOC of the HV battery. Otherwise, the engine may run longer than normal, resulting in a decrease in fuel efficiency.

    Click here 2020 - 2021 MY RAV4 HV [06/2020 - 12/2021]; HYBRID / BATTERY CONTROL: HV BATTERY STACK (for LITHIUM-ION BATTERY): BASIC INSPECTION

  • After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

PROCEDURE

1. READ VALUE USING TECHSTREAM

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / HV Battery / Data List / Hybrid/EV Battery Temperature 1 to 6.

Powertrain > Hybrid Control > Data List

Tester Display

Hybrid/EV Battery Temperature 1

Hybrid/EV Battery Temperature 2

Hybrid/EV Battery Temperature 3

Hybrid/EV Battery Temperature 4

Hybrid/EV Battery Temperature 5

Hybrid/EV Battery Temperature 6

(d) Read the Data List.

NOTICE:

If any of the temperatures listed in "Hybrid/EV Battery Temperature 1 to 6" are 50°C or more, leave the vehicle until the temperature drops to less than 50°C.

2. REMOVE HV BATTERY

Click here 2020 MY RAV4 HV [06/2020 - 08/2020]; HYBRID / BATTERY CONTROL: HV BATTERY (for LITHIUM-ION BATTERY): REMOVAL

3. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY

Click here 2020 MY RAV4 HV [06/2020 - 08/2020]; HYBRID / BATTERY CONTROL: BATTERY ECU (for LITHIUM-ION BATTERY): REMOVAL+

4. REMOVE NO. 1 HV BATTERY HOSE

Click here 2020 MY RAV4 HV [06/2020 - 08/2020]; HYBRID / BATTERY CONTROL: BATTERY ECU (for LITHIUM-ION BATTERY): REMOVAL+

5. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

Click here 2020 MY RAV4 HV [06/2020 - 08/2020]; HYBRID / BATTERY CONTROL: FUSE BOX (for LITHIUM-ION BATTERY): REMOVAL+

6. REMOVE HYBRID BATTERY TERMINAL BLOCK

Click here 2020 MY RAV4 HV [06/2020 - 08/2020]; HYBRID / BATTERY CONTROL: FUSE BOX (for LITHIUM-ION BATTERY): REMOVAL+

7. REMOVE NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the bolt, 3 nuts and No. 2 hybrid battery shield sub-assembly from the HV battery.

8. REMOVE NO. 1 HYBRID BATTERY COVER INTAKE DUCT

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the clip to disconnect the No. 1 hybrid battery cover intake duct from the HV battery.

(b) Disengage the claw of hybrid battery thermistor (sensor portion) and remove the No. 1 hybrid battery cover intake duct.

9. REMOVE BATTERY ECU ASSEMBLY

Click here 2020 MY RAV4 HV [06/2020 - 08/2020]; HYBRID / BATTERY CONTROL: BATTERY ECU (for LITHIUM-ION BATTERY): REMOVAL+

10. REMOVE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Disconnect the connector.

NOTICE:

Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

(b) Disconnect the connector.

(c) Disengage the claw.

(d) Remove the 4 nuts and No. 1 HV supply stack sub-assembly.

11. REMOVE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the nut and disconnect the ground terminal.

(b) Disengage the clamp.

(c) Disengage the claw.

(d) Remove the 4 nuts and No. 2 HV supply stack sub-assembly.

12. PERFORM RECOVERY INSPECTION

(a) Before returning the HV supply stack sub-assembly, make sure to perform a recovery inspection.

Click here 2020 - 2021 MY RAV4 HV [06/2020 - 12/2021]; HYBRID / BATTERY CONTROL: HV BATTERY STACK (for LITHIUM-ION BATTERY): RECOVERY INSPECTION